Professional Documents
Culture Documents
QQ6
Injection System
进气压力温度传感
Intake air temperature
器
pressure sensor
Cross-section view for sensor of air absolute pressure and temperature in intake manifold
1 Gasket 2 Stainless Steel Sleeve 3 PCB Board 4 Sensing Element 5 Housing 6 Pressure Bracket 7 Soldering 8
Bonded With Bonding Agent
1.3 Parameters of technical features
This sensor is designed to be mounted on the plane of auto engine intake manifold. The
pressure connecting pipe together with the temperature sensor protrudes inside the intake manifold
and an O gasket is used to enable atmosphere-proof.
If it is mounted on an auto through an appropriate method (picks up pressure from the intake
manifold and the pressure connecting pipe tilts down etc.), it can be ensured that no condensed water
will be formed on the pressure-sensitive element.
Drilling and fixing on the intake manifold must be carried out according to the supply drawing
so as to ensure a long seal and a good tolerance to fretting by agent.
The reliable contact of electric connection of a joint will mainly be affected by the joints of
components and parts, and it is also in relation to the material quality and dimensional precision of
the joint fitted with it on the harness.
1.4 Failure effects and judgment method
l Failure effects: spark extinction and poor idling etc.
l General Failure Reason:
1. Abnormal high voltage or inverse strong current occur during working;
2. The vacuum element is damaged during maintenance.
l Maintenance precautions: during maintenance, impinge using high pressure gas toward the
vacuum element is prohibited; when replacing the sensor after a failure is found, remember to
check if output voltage and current of the generator is normal.
l Simple measurement method:
1.4.1 Temperature sensor:
With the joint removed, turn the digital multimeter to Ohm shift, and then connect the two
meter pens respectively to 1# and 2# pins of the sensor; At 20℃, the rated resistance should be 2.5
kΩ±5%, and the other corresponding resistances can be measured out from the characteristic curve
in above chart. Analogue method can also be used when measuring, i.e., use an electric drier to blow
the sensor (be careful not to be too close to the sensor), and then observe the change of the sensor
resistance. At this point, the sensor resistance should fall.
1.4.2 Pressure sensor:
With the joint connected, turn the digital multimeter to DC Voltage shift, and then connect the
black pen to ground while the red pen respectively to 3# and 4# pins. Under idle speed state, 3# pin
should have a 5V reference voltage while the voltage on 4# pin should be around 1.3V (the actual
value depends on the model); Under no load state, when opening the throttle slowly, the voltage on
4# pin may change little; when opening the throttle rapidly, the voltage on 4# pin may reach around
4V instantly (the actual value depends on the model) and then fall to around 1.5V (the actual value
depends on the model).
2. Tachogenerator of Engine
Tachogenerator
tachogenerator
Installation of the
Oscillogram in Test
3. Phase Sensor
Phase sensor
With the joint removed, turn the digital multimeter to Ohm shift, and then connect the two
meter pens respectively to 1# and 2# pins of the sensor; At 20℃, the rated resistance should be
2.5kΩ±5% and the others can be measured out from the characteristic curve in above chart.
Analogue method can also be used when measuring, i.e., dip the working area of the sensor in boiled
water (dip for adequate time), observe the resistance change of the sensor, at this point, the resistance
should fall to 300Ω-400Ω(the actual value depends on the temperature of the boiled water).
5. Knock Sensor
5.3 Attentions
Knock sensor has a hole in the middle, through which it is fastened on the cylinder by a M8 bolt.
For the aluminum alloy block, using long bolt with 30 mm; for the casting iron, using 25mm bolt.
The tightening torque is 20±5Nm. The installation position should ensure that the sensor is liable to
receive vibration signals from all cylinders. Decide the optimal installation position of knock sensor
through modal analysis to the engine body. Generally, for a 4-cylinder engine, the knock sensor is
installed between 2# cylinder and 3# cylinder; for a 3-cylinder engine, it is installed at the center of
2# cylinder. Do not let liquid such as engine oil, coolant, brake fluid and water etc. contact the sensor
long. Use of gasket of any type is not allowed in installation. The sensor must cling to the cylinder
tightly through its metal surface. During wiring of sensor signal cables, do not make the signal
cables resonate; otherwise, they may break. Be sure to prevent turning on of high voltage between 1#
and 2# pins of the sensor; otherwise, damage to the piezoelectric element may occur.
6.1 Function:
The electronic throttle body can automatically open or close the throttle according to the
driver’s will to apply the accelerator pedal to let the engine work under the corresponding operating
mode. The electronic throttle has cancelled the conventional throttle guy and the opening of throttle
is controlled by ECU based on the signal from accelerator pedal and other signals (such as A/C,
power assisted steering, back and gearshift etc.) through an electronic step motor inside the
electronic throttle body. In addition to cancel of conventional idle speed by-pass and idle speed step
motor, there are also throttle position sensors on the electronic throttle body to feed back the opening
of the throttle. This suite of throttle position sensor is different from the common one; totally two
suites of throttle position sensors are installed inside the electronic throttle body to monitor
rationality of the signals from the latter; when any problem occurs in a certain signal, ECU can still
use the other suite of signals to work on.
6.2 Working principle:
The throttle driving motor is a micro motor, which is composed of multi steel stators in a circle
and a rotor, with one coil on each steel stator. The rotor is a permanent magnet with a nut at its center.
All stators coils are constantly power on. As long as the direction of current of one coil is changed,
the rotor will turn a certain angle. When the directions of current of all stator coils is changed in a
proper order, a rotating magnetic field is formed, which will drive the rotor made from permanent
magnet rotate along a certain direction. Its principle is just that of a micro direct current motor.
This motor drives a suite of special gear reducing mechanism and a bidirectional spring; when
the system is under power off condition, this mechanism can ensure that the opening of throttle valve
plate maintains at a safe position where is bigger than that for idle speed but not too high, so that the
vehicle can continue to run; if engine ECU has entered this failure mode, when applying the
accelerator pedal, the valve plate of the electronic throttle body will no longer act.
电子节气门
Electronic throttle
6.3 Failure diagnosis:
ECU can monitor short-circuit and break of coil of the throttle driving motor, and light the engine
failure light in case of such failure to let the engine enter failure mode, when the engine fails to
accelerate, has very poor driving performance and needs maintenance immediately.
7. Oxygen Sensor
The operation of the oxygen sensor is achieved by converting the concentration difference of
oxygen ion between inside and outside of the ceramic sensor element to the voltage signal output. It
bears the characteristic of solid electrolyte once the temperature of the ceramic sensor element
reaches 350℃. Because of the particularity of its materials, the oxygen ion can pass the ceramic
sensor element freely. Taking advantage of this characteristic, the concentration difference will be
converted to electric potential difference to form electric signal output. If the mixed gas is
comparatively thick, the oxygen ion thickness difference between inside and outside of the ceramic
tube will be higher and the potential difference will also be higher, then a mass of oxygen ion will
move from inside to outside, so, the output voltage is comparatively high (close to 800mV-1000mV);
If the mixed gas is comparatively thin, the oxygen ion thickness difference between inside and
outside of the ceramic tube will be smaller and the potential difference will also be smaller, then just
a few of oxygen ion will move from inside to outside, so, the output voltage is comparatively low
(close to 100mV). The signal voltage will mutate near theoretical equivalent air-fuel ratio (λ=1), see
the figure above.
Oxygen sensor
Every oxygen sensor bears a cable and the other end of the cable is the wire connector. The wire
connector of oxygen sensor produced by our company has four pins:
No.1 connects to the positive pole of heater power supply (white);
No.2 connects to the negative pole of heater power supply (white);
No.3 connects to signal negative pole (gray);
No.4 connects to signal positive (black).
9. Injector
With the joint removed, turn the digital multimeter to Ohm shift, and then connect the two meter
pens respectively to the two pins of primary winding. At 20℃, the resistance should be 0.42-0.58Ω,
while this value of secondary winding should be 11.2-14.8kΩ.
11. Spark Plug
The operating conditions of spark plug is extremely inclement, it is exposed to high pressure,
high temperature and impact as well as strong corrosion from combustion product; therefore, it is a
wearing part.
Mono-pole Triple-pole
11.4 Judge if the vehicle status matches with the spark plug type through color of spark plug
Yellow, brown yellow normal indicates that the combustion status of mixed air is normal
Black with carbon deposit carbon deposit check if the spark plug type matches and then
replace with the spark plug with lower heat value (slow heat radiation).
Black with blot soot clean if the injector nozzle is dirty
Dilute if the mixture ratio of oil gas is too big.
Check ignition coil etc. if the high voltage is poor.
Black with oil stain combustion of engine oil check sealing status of the seal ring and if
scratch is present on the cylinder wall.
Pearl overheating check if the spark plug type matches, and then replace with the spark plug
with lower heat value (rapid heat radiation).
11.6 Regular replacement and use overdue
The spark plug is the low-value consumption goods. Though cheaper compared with other
matching parts, its ignition performance directly affects the performance of the engine. Therefore, it
needs regular replacement. For the spark plug used in our vehicles, we suggest that you should
replace the spark plug at the following mileages: 10,000-15,000 km (single electrode);
15,000-25,000 km (multi electrode).
Ignition performance fall of spark plug will make fuel consumption rise and power drop off.
The economic loss caused by excessive fuel consumption unconsciously will even afford to
hundreds of new spark plugs. Use overdue makes the working condition of the engine poor in long
term and brings some damage to the engine.
11.7 Inspection and maintenance of the spark plug
The inspection items for spark plug mainly include carbon deposit, electrode burn through, gap,
and sealing and spark jump performances of the spark plug etc.
The electrode gap of the spark plug should be 0.7-0.9mm. Too small electrode gap will reduce
the breakdown voltage and weaken the spark intensity; while too big electrode gap will increase the
voltage required by the spark plug and cause spark out, especially when the ignition coil is aging and
the ignition system is in poor maintenance, spark out is more liable to occur.
Common failures of spark plug: fall in sealing performance, air leak and soot at the air leakage
position. The above failures can be inspected and judged through sealing performance test and spark
jump test. Both sealing performance test and spark jump test can be conducted on a spark plug
cleaning tester.
It is unscientific that some drivers and maintenance professionals remove the spark plug from
the engine, place it on the cylinder head and inspect if it is in sound conditions using high voltage of
the vehicle. In this test, the spark plug electrode is under an atmosphere other than a gas pressure of
over 800KPa, its working pressure. Therefore, spark jump of a spark plug under an atmosphere
does not indicate that it will also reliably produce spark jump under a high pressure conditions in the
cylinder.
It is required that carbon deposit disposal and proper adjustment of spark plug gap should be
done after a mileage of 10,000-15,000 km in its lifetime. When the temperature in cylinder rises, the
electrode gap should be increased properly. That is, increase the electrode gap in summer while
reduce it in winter. If the mixed air is strong, the electrode gap should be increased; otherwise,
decreased. In plain region, the electrode gap should be decreased while in plateau region, increased.
12.1 Function:
Carbon canister solenoid valve is a device used to enable the fuel steam in fuel tank to enter
cylinder to combust through control of ECU. Through controlling duty cycle of a solenoid valve,
ECU can accomplish open and close of the solenoid valve.
12.2 Working principle:
The canister control valve is composed of solenoid, armature iron and valve etc. There is a filter
net at the inlet. The airflow through the canister control valve at one hand depends on the duty cycle
of the electric pulse output of canister control valve by ECU, and at another hand depends on the
pressure difference between the inlet and the outlet of the canister control valve. The canister control
valve will be closed when there is not any electric pulse.
13.1 Function:
The electronic accelerator pedal has cancelled the conventional throttle guy and the position of
accelerator pedal is fed back to ECU by means of electronic signal, through which ECU can
calculate and control the action of the electronic accelerator pedal. Two sets of Hall sensors are
integrated in the pedal; ECU can compare and analyze the two signals, if one signal is improper,
ECU will duly access the other signal and light the failure indicator.
13.2 Working principle:
The pedal is a Hall sensor. The fixed Hall generator and signal processing circuit are installed
on fixed mounting of the pedal. The two permanent magnets with different magnetic sheet thickness
act together with the pedal. When the pedal acts, the magnetic flux passing the Hall generator will
also change accordingly, the signal processing circuit will process these signals and then send them
to ECU.
13.3 Detection:
The relationship between the two signals of the accelerator pedal is that signal 1 is equal to
signal voltage.
At idle speed position, the voltage of signal 1 is 4.59 and that of signal 2 is 4.30. When the
pedal is at middle position, the voltage will be the minimum; when the pedal is at either end position,
the voltage will be the maximum.
14.1 Function:
Three-way catalytic converter is used to convert the noxious gas in tail gas into such innocuous
gases as carbon dioxide and water etc. At 300-800℃, the conversion efficiency of three-way
catalytic converter is maximum; with a temperature below this scope, the conversion efficiency will
be very poor, while, with a temperature above this scope, the three-way catalytic converter may be
burnt out. Three-way catalytic converter can exert better conversion efficiency only when the
oxygen sensor works. In control strategies of ECU, there are several protective modes for three-way
catalytic converter, and ECU can protect the three-way catalytic converter by regulating air-fuel ratio
and ignition advance angle.
15.1 Function:
In order to abstract heat from engine system and from condenser with A/C turned on, fan
control is affected by the signal to ECU sent by water temperature sensor; When water temperature
is high (above the threshold value set by ECU), the fan will run, and when water temperature is low
(below the threshold value set by ECU), the fan will also run; with A/C turned on, the fan will run at
low speed.
15.2 Composition:
DC electric motor double fan (high and low speed change).
15.3 Installation requirements:
The fan is installed between the rear of radiator and the engine, be careful when installing: not
to damage fin of fan blade, otherwise, running noise of the fan will increase, if serious, it may lead to
sharp fall of heat radiation effect of the engine.
15.4 Failure diagnosis:
Fan control circuit is a short or open circuit to ground;
The fan has failure itself;
Too loud fan noise;
Failure in power supply circuit of fan.
15.5 Troubleshooting:
First, validate whether it is a high speed fan system problem or a low speed fan system problem.
Provided that this is a fan control system problem, use a diagnostic tester to locate the failure point,
and then validate whether it is a short-circuit or a break in control circuit.
Failure symptom: the fan failure may result in rise of engine coolant temperature and poor
refrigeration of A/C system.
16.1 Function:
制动开关传感器是将刹车信号送给 ECU,ECU 根据(原文不全)
16.2 Working principle:
Inside the brake switch, there are two mutually independent switches with one normal close and
the other normal open. After applying the accelerator pedal, the former normal close switch turns to
be normal open, while the normal open one turns to be normal close. Both signals will be sent to
ECU to be used to control other systems. Whenever the two signals disaccord, ECU will enter failure
mode, the electronic throttle will not respond when applying the accelerator pedal and the engine
will maintain idle speed working state.
Composition: the double brake switch is installed on the bracket of the brake pedal and contains two
independent switches inside.
Installation requirement: the assembly is installed on the pedal and there is a thread adjusting
mechanism on the switch for stroke adjustment of the switch and effective stroke adjustment of the
brake switch.
17.1 Function:
Clutch position switch provides ECU with the signal of clutch position, but this signal can only
be used to distinguish between disengaging and engaging positions of the clutch.
17.2 Working principle:
ECU provides clutch position switch with a 12V power supply; when the clutch is under
disengaging state, the power supply will ground and ECU will lose 12V high potential signal, by
which the position of the clutch can be judged.
By receiving the A/C signal from A/C switch, ECU can control working of A/C compressor.
ECU also can receive the signals from high and low pressure switches of A/C to ensure safety of A/C
system. When A/C signal is sent to ECU through high and low pressure switches, if the low pressure
switch breaks, ECU will not receive the A/C signal; the compressor is thus unable to work. If A/C
system has a too high pressure, the high pressure switch will break and A/C signal can not be
provided to ECU; so, ECU will immediately cut off the compressor. When system pressure is normal
or a little higher (medium pressure), the medium pressure switch will cut in; thus, ECU can control
the fan to run immediately at high speed to ensure a system pressure within the normal range.
Cut off pressure of the low pressure switch: 0.12Mpa
Cut-in pressure of the medium voltage switch: 1.6Mpa
Cut off pressure of the high pressure switch: 3.2Mpa
Through evaporator temperature sensor of the A/C system, ECU
can also protect the A/C system and prevent evaporator case from
freezing. When the temperature provided by the evaporator
高 中
Medium voltage switch
低 压
压 开
compressor; when the temperature is above this degree, ECU will 开 关
automatically engage the compressor to let it work. 关
A/C 开关
switch
Chapter Two Fundamental Principle for Failure Diagnosis of
Electronic Fuel Injection System
The ECU monitors sensor, actuator, related circuit, malfunction indicator and
battery voltage etc., and even EUC itself continuously. At the same time, the ECU
inspect the reliability test on sensor signal output, actuator driving signal and internal
signal (e.g.: closed loop control, knock control, idle speed control and accumulator
voltage control etc.). ECU will set the malfunction record on RAM malfunction
memory immediately once the malfunction or the unlikelihood signal is detected. The
failure information records are stored in the form of diagnostic trouble code (DTC) and
are displayed in the precedence order of occurrence of the failures.
Failures can be divided into “stable state failures” and “random failures” (for example,
caused by transient open circuit of wires or poor contact of inserted parts) by failure
frequency.
2. Failure State
Once duration of occurrence of an identified failure exceeds the given stabilization time
for the first time, ECU will account it as a stable failure and then store it as a “stable
state failure”. If this failure disappears, it will be stored as a “random failure” and
“non-existent”. If this failure is identified again, it will still be a “random failure”, but a
“existent” early failure that will not affect average service of the engine.
3. Failure Types
For every identified failure, a separate frequency counter numerical value (Hz) will be
set.
This numerical value (Hz) for frequency counter determines the time this failure
information record will be stored in memory after the identified failure disappears (after
troubleshooting).
When a failure is identified for the first time, Hz will be set as its initial value 40. If
failure status does not change, then this numerical value will maintain all along.
Once it is identified that this failure has disappeared and the state has held for a certain
time, whenever the engine starts with success (its engine speed has exceeded the value
at end of starting) once, Hz will decrease by 1. At this point, ECU will believe that this
failure has disappeared, but the failure information record still exists.
If a failure (for example, as a result of poor contact) frequently appears and disappears,
then Hz will increase by 1, but will not exceed its given upper limit value 100.
If value of Hz has been decreased to zero, the failure information records in this failure
memory will be completely cleared.
5. Limp Home
For some identified significant failures, when duration exceeds the given
stabilization time, ECU will take appropriate software countermeasures, for example,
closing some control functions such as closed loop control of oxygen sensor etc. and
setting substituted values for some data that are considered to be suspect and so forth.
At this point, though the working condition of the engine is comparatively poor, the
auto can still run. The purpose to do this is to enable the auto limply run home or to a
service station for overhaul, so as to avoid the embarrassment that the auto breaks down
on highway or afield. Once it is identified that the failure has disappeared and Hz has
fell to below 40, use of normal data will be resumed again.
6. Failure Alert
In the electric control system, when failure take places in any of such important
parts as ECU, absolute pressure sensor in intake manifold, throttle position sensor,
coolant temperature sensor, knock sensor, oxygen sensor, phase sensor, injector, two
driver stages of step motor of idle speed actuator, canister control valve, or fan relay at
corresponding failure location, ECU will give an alarm through lightening of failure
indicator lamp until this failure location restores.
7. Readout of Failure
The failure information records can be called out of ECU through a trouble diagnosis
tester. If the failure relates to the function of mixed air (fuel and air) proportional
regulator, then the engine must at least run for 4 minutes before reading out failure
information records; especially for failure in oxygen sensor, be sure not to detect data
until the engine runs and warms up.
- -
Figure 3-1 ISO 9141-2 Standard Diagnostic Connector
After the failure is removed, the failure information records in memory should be
cleared. The diagnostic trouble code can be cleared through the following approaches:
When the numerical value of frequency counter in ECU reaches zero, the failure
information records in failure memory will be automatically cleared.
Employing fault diagnostic tester to clear records of failure with the instruction of “reset
memory for records of failure”.
Pulling out connectors of ECU or disconnecting wires of battery to clear records of
failure in external ram.
9. Failure Locating
After obtaining failure information records through above means, only rough
location where the failure takes place is aware, but this does not mean that the failure
has been located; because the cause that triggers a piece of failure information may be
damage of electric element (such as sensor, actuator or ECU etc.), lead break, lead
short-circuit to ground or anode of battery, even may be mechanical failure.
The failure is intrinsic and the result of its extrinsic representations is a variety of
symptoms. After a symptom is found, first, check for failure information records with a
trouble diagnosis tester or based on the flash code, after that, remove the correlated
failure in accordance with the failure information, and then locate the failure based on
symptom of the engine.
Failure
No. DTC Explanation class
1 P0016 Improper relative installation position between camshaft and crankshaft class5
2 P0030 Failure in heating control circuit of upstream oxygen sensor class31
3 P0031 Too low voltage in heating control circuit of upstream oxygen sensor class31
4 P0032 Too high voltage in heating control circuit of upstream oxygen sensor class31
5 P0105 Signal failure of intake air pressure sensor class31
6 P0106 Improper signal from intake air pressure sensor class31
7 P0107 Too low voltage in signal circuit of intake air pressure sensor class31
8 P0108 Too high voltage in signal circuit of intake air pressure sensor class31
9 P0112 Too low voltage in signal circuit of intake air temperature sensor class5
10 P0113 Too high voltage in signal circuit of intake air temperature sensor class5
11 P0117 Too low voltage in signal circuit of engine coolant temperature sensor class31
12 P0118 Too high voltage in signal circuit of engine coolant temperature sensor class31
13 P0121 Improper signal from electronic throttle position sensor 1 class34
14 P0122 Too low voltage in signal circuit of electronic throttle position sensor 1 class34
15 P0123 Too high voltage in signal circuit of electronic throttle position sensor 1 class34
16 P0130 Improper signal from upstream oxygen sensor class31
17 P0131 Too low voltage in signal circuit of upstream oxygen sensor class31
18 P0132 Too high voltage in signal circuit of upstream oxygen sensor class31
19 P0134 Failure in signal circuit of upstream oxygen sensor class31
20 P0201 Failure in 1# cylinder injector control circuit class5
21 P0202 Failure in 2# cylinder injector control circuit class5
22 P0203 Failure in 3# cylinder injector control circuit class5
23 P0204 Failure in 4# cylinder injector control circuit class5
24 P0219 Engine revolution exceeds the maximum revolution limit class5
25 P0221 Improper signal from electronic throttle position sensor 2 class34
26 P0222 Too low voltage in signal circuit of electronic throttle position sensor 2 class34
27 P0223 Too high voltage in signal circuit of electronic throttle position sensor 2 class34
28 P0261 Too low voltage in 1# cylinder injector control circuit class5
29 P0262 Too high voltage in 1# cylinder injector control circuit class5
30 P0264 Too low voltage in 2# cylinder injector control circuit class5
31 P0265 Too high voltage in 2# cylinder injector control circuit class5
32 P0267 Too low voltage in 3# cylinder injector control circuit class5
33 P0268 Too high voltage in 3# cylinder injector control circuit class5
34 P0270 Too low voltage in 4# cylinder injector control circuit class5
35 P0271 Too high voltage in 4# cylinder injector control circuit class5
36 P0321 Improper signal of crankshaft top dead center class33
37 P0322 Engine speed signal failure class33
38 P0324 Failure in knock signal processing chip and its circuit class5
39 P0327 Too low voltage in signal circuit of knock sensor class31
40 P0328 Too high voltage in signal circuit of knock sensor class31
41 P0340 Failure in signal circuit of phase sensor class5
42 P0341 Improper signal from phase sensor class5
43 P0342 Too low voltage in signal circuit of phase sensor class5
44 P0343 Too high voltage in signal circuit of phase sensor class5
45 P0444 Failure in control circuit of canister control valve class31
46 P0458 Too low voltage in control circuit of canister control valve class31
47 P0459 Too high voltage in control circuit of canister control valve class31
48 P0480 Failure in relay control circuit of electronic cooling fan (low speed) class5
49 P0481 Failure in relay control circuit of electronic cooling fan (high speed) class5
50 P0501 Improper speed signal class5
51 P0504 Improper signal of brake pedal A/B class5
52 P0506 Engine speed under idle speed control is below the target idle speed class5
53 P0507 Engine speed under idle speed control is above the target idle speed class5
54 P0537 Too low voltage in signal circuit of evaporator temperature sensor class5
55 P0538 Too high voltage in signal circuit of evaporator temperature sensor class5
56 P0560 Improper system voltage signal class33
57 P0562 Too low system voltage signal class33
58 P0563 Too high system voltage signal class33
59 P0571 Failure in signal circuit of brake pedal class5
60 P0601 Failure in EEPROM of ECU class33
61 P0602 Unprogrammed failure in ECU class33
62 P0604 Failure in RAM of ECU class34
63 P0605 Failure in ROM of ECU class34
64 P0606 Safety monitoring function failure of electronic throttle class34
65 P0627 Failure in control circuit of fuel pump relay class33
66 P0628 Too low voltage in control circuit of fuel pump relay class33
67 P0629 Too high voltage in control circuit of fuel pump relay class33
68 P0645 Failure in control circuit of A/C compressor relay class5
69 P0646 Too low voltage in control circuit of A/C compressor relay class5
70 P0647 Too high voltage in control circuit of A/C compressor relay class5
71 P0688 Improper output voltage of main relay class33
72 P0689 Too low output voltage of main relay class33
73 P0690 Too high output voltage of main relay class33
74 P0691 Too low voltage in relay control circuit of electronic cooling fan (low speed) class5
Too high voltage in relay control circuit of electronic cooling fan (low
75 P0692 speed) class5
Too low voltage in relay control circuit of electronic cooling fan (high
76 P0693 speed) class5
Too high voltage in relay control circuit of electronic cooling fan (high
77 P0694 speed) class5
78 P0704 Improper clutch pedal signal class5
79 P1336 Restrictive effect of safety monitoring torque of electronic throttle class34
The deviation between physical location and target location of electronic
80 P1545 throttle overruns class34
81 P1558 Too large opening resistance of electronic throttle class34
82 P1559 Failure in self-study process of electronic throttle class34
System voltage fails to meet the conditions for self-study of electronic
83 P1564 throttle class34
Failure in self-study of initialization of lower limit position of electronic
84 P1565 throttle class34
85 P1568 Too large restoration resistance of electronic throttle class34
86 P1579 Fails to meet the conditions for self-study of electronic throttle class34
87 P1604 Failure in self-study of gain adjustment of electronic throttle class34
88 P1610 Unprogrammed error in Secret Key and Security Code class39
89 P1611 Security Code acceptance error class39
90 P1612 Challenge request failed class36
91 P1613 Immo Code request failed class36
92 P1614 Transponder check error class36
93 P1677 Too high voltage in control circuit of detector lamp (SVS) class5
94 P1678 Too low voltage in control circuit of detector lamp (SVS) class5
95 P1679 Failure in control circuit of detector lamp (SVS) class5
96 P2106 Failure in driver stage of electronic throttle class34
Too low voltage in signal circuit of electronic accelerator pedal position
97 P2122 sensor 1 class34
Too high voltage in signal circuit of electronic accelerator pedal position
98 P2123 sensor 1 class34
Too low voltage in signal circuit of electronic accelerator pedal position
99 P2127 sensor 2 class34
Too high voltage in signal circuit of electronic accelerator pedal position
100 P2128 sensor 2 class34
101 P2138 Improper signal from electronic accelerator pedal position sensor class34
Self-study value of closed loop air fuel ratio control is above the upper limit
102 P2177 (normal load zone) class5
Self-study value of closed loop air fuel ratio control is below the lower limit
103 P2178 (normal load zone) class5
Self-study value of closed loop air fuel ratio control is above the upper limit
104 P2187 (idle speed zone) class5
Self-study value of closed loop air fuel ratio control is below the lower limit
105 P2188 (idle speed zone) class5
Self-study value of closed loop air fuel ratio control is above the upper limit
106 P2191 (heavy load zone) class5
Self-study value of closed loop air fuel ratio control is below the lower limit
107 P2192 (heavy load zone) class5
Engine
theft-proof
module 1
Failure codes: P012, P0122, P0123, P022, P0222, P0223, P1336, P154, P1558, P1559, P1564,
P1565, P1568, P1579, P1604
No. Operating steps Result Follow up steps
1 Put the ignition switch to “ON”. Next step
2 Pull out the joint of throttle position sensor on Yes Next step
harness; use a multimeter to check if the
No 5
magnitude of voltage between its 3# and 5# pins
is around 12V and if a 5V voltage is present
between 6# and 2# pins.
3 Use a multimeter to check if the resistance Yes Next step
values between 1#, 4# and 6# pins of the sensor No Replace the sensor
are between 0.5kΩ and 1.6kΩ.
4 Meanwhile, use a multimeter to check if it is Yes Replace the sensor
break or short circuit between 1#, 4# and 6#
pins of throttle position sensor and ECU38#, No Replace ECU
54#, 36#; or, turn blade of the throttle to observe
if its resistance value jumps and if the resistance
values between 1#, 4# and 6# change
accordingly with rotation of throttle.
5 Connect an adaptor between ECU and harness, Yes Repair or replace
use a multimeter respectively check if it is break wire harness
or short circuit between 1#, 2#, 6# and 4# pins
No Replace ECU
of the sensor and 10#, 32#, 36# and 54# pins of
ECU joint.
Note: This auto adopts the electronic throttle body and has cancelled former step motor,
and the functions that were accomplished by the stop motor on a common throttle body
are now completely accomplished by the throttle driving motor. The electronic throttle
can not be repaired and failure rate of the throttle body is very low, if damaged,
replacing the assembly is the only choice to deal with the problem.
Special attention: The electronic throttle body can not be disassembled and repaired at
service station; in addition, after replacing electronic throttle body, be sure to let it carry
out self-study; otherwise, unsteady working at idle speed of engine may occur. See also
the section about electronic throttle for detailed study scheme. Maintenance of the
throttle body is analogous to that of the common valve body.
11.2 Knock Sensor failure
Note: Generally, knock sensor is not liable to damage. When disassembling and installing the knock
sensor, be careful not to leave dirt on the contact surface of the sensor and the engine body and do
not add any gasket. If the sensor is damaged, it will have an comparatively great effect on
economical efficiency and emission of the engine. After the knock sensor is damaged, the electric
control system of the engine will lock ignition advance angle of the engine at a fixed ignition angle,
so, the acceleration performance of the engine will fall and economical efficiency and emission of
the engine will also be greatly affected.
11.3 Air Pressure Sensor Failure
Note: In case the sensor shorts to 5V or 12V power supply or ground, the engine may not start up or
stop running.
11.4 Front Oxygen Sensor Failure
Note: when checking data flow of the oxygen sensor, be sure to note working position
of the engine and let the working temperature of the engine reach the normal value,
because the oxygen sensor only can start to work normally when the temperature is over
300℃.
11.5 Rear Oxygen Sensor Failure
Note: The characteristics and operating principle of rear oxygen sensor is basically the
same as those of front oxygen sensor, in special conditions, they can be interchanged to
use. The only difference between them is their different installation sites (working
atmospheres), therefore, during maintenance and diagnostic processes of the vehicle,
please pay attention to some inspection techniques for front and rear oxygen sensors.
11.6. Coolant Temperature Sensor Failure
5 Start the engine, while engine coolant temperature Yes Next step
rises, check if the voltages on two wires of the No Replace the sensor
sensor falls as water temperature of the engine
rises.
6 Start the engine, disconnect the connector of water Yes Check other part
temperature sensor, and then observe if cooling No Replace the ECU or
fan of the engine starts up and runs at high speed. the circuit
11.7 Failure in Driver Stage of Injector
Failure codes: P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270,
P0271
No. Operating steps Result Follow up steps
1 Close the ignition switch, and the engine stops. Next step
2 Pull out each electromagnetic injector joint on Next step
harness in turn, and then lap the two pins of
multimeter between 2# pin of the joint and the
engine.
3 Put the ignition switch to “ON”. Observe if, at the Yes Repeat 2
instant when the ignition switch cuts in, the
multimeter displays an around 12V voltage value All yes 6
of battery (mainly check if the injector has power No Next step
supply, which is provided by main relay).
4 Use a multimeter to check in turn if it is break or Yes Repair or replace
short circuit between 87# pin of output terminal of harness
main relay of the engine and 1# pin of each No Next step
electromagnetic injector joint.
5 Repair or replace fuel pump relay and main relay Yes Repair or replace
and their circuits. harness
6 Connect the adaptor between ECU and harness; No Next step
use a multimeter to check in turn if it is break or
short circuit between 27#, 7#, 47# or 6# pins of
ECU and 2# pin of each corresponding
electromagnetic injector joint on harness.
7 Use a multimeter to check in turn if a resistance Yes Repeat 7
between 12Ω and 16Ω is present at 20℃ between All yes Next step
1# and 2# pins (and resistance value of injector) of No Replace the
the electromagnetic injectors. electromagnetic
injector
8 Re-plug all electromagnetic injector joints, engage Yes Repeat 8
the gear to neutral position, start the engine, and
No Replace ECU
then let it run at idle speed. Pull out all
electromagnetic injector joints on harness in turn.
Whenever a joint is pulled out, observe if engine
vibration is aggravated accordingly (equivalent to
spark out experiment).
Note: The damage probability of injector is very low; its main failure is carbon deposit
in injection nozzle, which may result in atomization of fuel injection, poor spray and
unsteady idle speed of engine; therefore, when inspecting, above failure should be
inspected as an emphasis.
11.8 Failure in Driver Stage of Canister Control Valve
Note: The carbon canister solenoid valve is used for the emission control system, a
system set up for environmental protection and air pollution prevention. When engine
runs at idle speed or under heavy load operating mode, the solenoid valve will not
participate in the work. A malfunction of this solenoid valve will result in unsteady
operating mode of the engine. These details should be noted during maintenance
process.
11.9 Failure in Driver Stage of Malfunction Indicator Lamp (MIL)
Note: The malfunction indicator lamp is controlled by ECU. When a failure occurs in
the system, ECU will control the malfunction indicator lamp to light. There are two
kinds of malfunction indicator lamps on this auto (engine failure indicator lamp and
EPC), but the engine failure indicator lamp on the instrument may be shielded in the
system, that is, when a failure occurs, EPC lamp will light, which should be noted
during maintenance process.
11.10 Failure in Driver Stage of 1#, 2# Coils of Step Motor
Note: Much about failure diagnosis for other parts has been involved above.
11.11 Crankshaft Position Sensor Failure
Note: The camshaft position sensor is an auxiliary sensor and has great effect on emission of the system.
When failure occurs in this sensor, the vehicle will be difficult to start; though the vehicle will be
basically normal after startup, driving restrictive practice will be found on the engine and the maximum
revolution of engine can not exceed 4000rpm.
11.12 Craftshaft Position Sensor Failure
Note: The ignition coil is mainly used to provide ignition system of engine with ignition energy. The
failure rate of the coil itself is very low, but its failure probability can not be completely excluded. When
failure occurs in ignition coil, the ignition energy of engine will be deficient, which may further lead to
such failures as unsteady idle speed of engine and emission deterioration.
11.13 Accelerator Pedal Position Sensor Failure
Symptom
12.1 Perform Preliminary Inspection First before Following the Steps for
Implementation of Failure Diagnosis by Engine Symptom.
(1) Make sure that ECU and failure indicator lamp (or EPC lamp) have no off-normal
phenomenon (excluding the models that have no failure indicator lamp).
(2) Use a failure diagnostic tester to check and make sure no failure information record
exists.
(3) Employ failure diagnostic tester to check that hot idle data from electronic control
system fall within normal scope.
(4) Validate that the failure effect the owner complained exists and then locate the exact
position of the symptom. Please note that the information provided by the customer is
very important, especially the failure symptoms, occurrence time, position and if any
other failure symptoms occurred before; these information can help technical personnel
rapidly and effectively judge the failure, thus increasing maintenance speed and
improving maintenance quality.
Then check the appearance:
Check that grounding of wire harness is clean and firm.
Check that vacuum pipeline is unbroken, twisted and in right connection.
Check that there is no obstruction in pipe.
Check that air intake pipe is not squashed or damaged.
Check that the seal between throttle body and intake manifold is perfect.
Check that ignition cable of ignition system is unbroken, no ageing and in right wiring.
Check that wires are in right connection, no loosing or poor connection for connectors.
12.2 The Engine Does not Rotate or Rotates Slowly when Starting
Note: When this problem occurs, mainly inspect voltage, starter and ground system. In
modern sedan, lubricant has little effect on startup of the vehicle, so, basically, it needs
not to allow for lubricant problem, but the problem if the engine has too large self
resistance should be taken into consideration.
12.3 When Starting, Engine Can be Dragged to Rotate but Can not Start
with Success.
13 Check if the fuel pressure value is below 400 Yes Next step
kPa. No 17
14 Close the fuel manometer valve. Re-engage the Yes Next step
ignition switch to let the fuel pump run for a No 16
period of time, and then check if fuel pressure
can be built up.
15 Open the valve of fuel gauge and clamp the oil Yes Check other part
return pipe by oil return baffle so that the oil can No Repair or replace
not return. Check if the oil pressure occurs the fuel pump
immediately.
16 Check if there is leakage or jam in oil intake Yes Repair or replace
pipe. oil intake pipe
No Replace oil pump
17 Check if the oil return pipe is bended or Yes Repair or replace
jammed. oil return pipe
No Replace fuel
pressure regulator
18 Check if it is break or short circuit between 1#, Yes Repair or replace
2# pins of crankshaft position sensor and 34#, the harness
15# pins of ECU. No Next step
22 Check if the reason for the failure on starting is Yes Remove the
about mechanism, such as much cylinder mechanical failure
clearance, cylinder leaking, and so on. No Replace ECU
Note: When checking this problem, if all parts in electronic fuel injection system are
normal, consider if mechanical part of the engine works normally, or if cylinder
pressure is normal and if air leakage exists and so forth.
12.4 Warm Starting Difficulty
Note: Warm starting difficulty is in connection with many systems, such as battery,
throttle body and water temperature sensor etc. as well as mechanical part of the engine,
such as valve sealing. Thermal expansion of engine under warm state may lead to rise of
engine resistance.
12.5 Engine Speed is Normal, but it is Difficult to Start at any Time
Note: Note if theft-proof system has started up. After theft-proof system has started up,
when starting the engine, the staring motor can run normally, but the engine can not
start; therefore, please note if this system can work normally.
12.6 Cold Starting Difficulty
No Next step
7 When engine coolant is at low temperature, pull Yes Next step
out electronic throttle body joint on harness and No Check the electric
observe if engine revolution will rise. throttle body
8 Connect fuel manometer valve. Let 86# pin of fuel Yes Next step
pump relay directly ground. Turn on ignition
No 12
switch to make fuel pump relay and fuel pump
work, and then check if fuel pressure is at around
400kPa.
9 Use a special joint to directly provide a 12V Yes 11
electricity and ground wire from battery to injector No Next step
and check if the injector works normally.
10 Clean out the fuel injector and look if it can work Yes Next step
correctly. No Replace fuel
injector
11 Check if fuel is deteroprated or moisture. Yes Replace fuel
No 17
12 Check if the fuel pressure value is below 300 kPa. Yes Next step
No 16
13 Close the fuel manometer valve. Re-engage the Yes Next step
ignition switch to let the fuel pump run for a No 15
period of time, and then check if fuel pressure can
be built up.
14 Open the valve of fuel gauge and clamp the oil Yes Check fuel pressure
return pipe by oil return baffle so that the oil can regulator and fuel
not return. Check if the oil pressure occurs pump
immediately. No Repair and replace
fuel injector and oil
pipe
15 Check if the oil intake pipe is leaky or jammed. Yes Repair or replace
oil intake pipe
No Replace oil pump
16 Check if the oil return pipe is bended or jammed. Yes Repair or replace
oil return pipe
No Replace fuel
pressure regulator
or fuel pump
17 Check if the pressure of cylinder is normal. Yes Next step
No Troubleshooting
18 Check if the engine air intake system is leaky. Yes Repair
No Next step
19 If air cleaner or airflow sensor is choked. Yes Repair or replace
No Replace ECU
Note: The cold starting problem relates to more failure points, among which water
temperature sensor is comparatively important, because it is the major parameter for
determination of injection pulse-width when starting the engine. In case of a water
temperature sensor failure or it generates a false signal, the system can not judge the
temperature and starting difficulty may occur.
12.7 Unsteady Idle Speed at Any Time
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Check if electronic throttle system of engine Yes Repair or replace
works normally. the electronic
throttle
No Next step
3 Turn on ignition switch, connect an adaptor Yes Check wires and
between ECU and harness, and then check if the plugs
voltage between 17# and 42# pins of ECU,
between 39# and 17# pins of ECU (signal output No Next step
terminal of intake air temperature sensor and
coolant temperature sensor) as well as 64#, 65#,
66#, 67# pins of ECU (for control of DC motor) is
normal.
4 Let engine run at idle speed, spark out cylinder in Yes 8
turn, and observe if engine revolution will fall and No Next step
fluctuate (cut fuel to injector).
5 Check the fuel injectors of each cylinder and look Yes Next step
if they are in right conditions. No Check fuel injector
and wires
6 Check if resistance value of ignition cable of each Yes Next step
cylinder is normal (can not exceed 16kΩ). No Replace
7 Check if ignition system works normally. Yes Maintain
No Next step
8 Check if the spark plug is in right conditions. Yes Next step
No Replace spark plug
9 Connect fuel manometer valve. Short 30# and 87# Yes Next step
pins of fuel pump relay to make the fuel pump
run, and then check if fuel pressure is around No 13
400kPa.
10 Use a special joint to directly provide a 12V Yes 12
power supply and intermittent ground wire signal No Next step
from battery to injector and check if the injector
can work intermittently.
11 Clean out the fuel injector and look if it can work Yes Next step
correctly. No Replace fuel
injector
12 Check if fuel is deteroprated or moisture. Yes Replace fuel
No 18
13 Check if the fuel pressure value is below 300kPa. Yes Next step
No 17
14 Close the fuel manometer valve. Re-engage the Yes Next step
ignition switch to let the fuel pump run for a No 16
period of time, and then check if fuel pressure can
be built up.
15 Open the valve of fuel gauge and clamp the oil Yes Replace fuel
return pipe by oil return baffle so that the oil can pressure regulator
not return. Check if the oil pressure occurs No Repair and replace
immediately. fuel injector and oil
pipe
16 Check if there is leaking or jam in oil intake pipe. Yes Repair or replace
oil return pipe
No Replace oil pump
17 Check if the oil return pipe is bended or jammed. Yes Repair or replace
oil return pipe
No Replace fuel
pressure regulator
18 Check the pressure of air intake pipe and if the Yes Use detergent to
sense port of air intake temperature sensor is wash
jammed. No Next step
19 Let engine run at idle speed, after coolant Yes Next step
temperature reaches the active temperature of No Check the oxygen
closed loop control, observe if the oxygen sensor sensor and harness
works normally (rapidly fluctuate between 0.1V
and 0.9V).
Check if the engine air intake system is leaky. Yes Remove leakage
20 No Next step
21 Check if the pressure of cylinder is normal. Yes Next step
No Troubleshooting
22 Let engine run at idle speed, after coolant Yes Replace ECU
temperature reaches normal value, then use a
No Check other part
special diagnostic tester to check if ignition
advance angle is within the standard scope.
Note: Unsteady idle speed relates to many systems, such as air leak, carbon deposit and
throttle body etc.; before replacing a part, make sure that air cleaner, spark plug and
ignition system of engine are normal.
12.8 Unsteady Idle Speed during Warming up Process
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Check the air cleaner and look if it is open. Yes Next step
No Replace
3 After starting successfully, check if air intake Yes Next step
consumption of the engine at idle speed is around No Eliminate the
300Kg/h (remember to check if cylinder pressure leakage failure of
is normal). air intake system
4 Turn on ignition switch, connect an adaptor Yes Next step
between ECU and harness, and then check if the
voltage between 17# and 42# pins of ECU, No Overhaul
between 39# and 17# pins of ECU (signal output
terminal of intake air temperature sensor and
coolant temperature sensor) as well as 64#, 65#,
66#, 67# pins of ECU (for control of DC motor) is
normal.
5 Before finish of warming up of engine, pull out Yes Next step
the joint on electronic throttle body and observe if No Check the electric
engine revolution will change. throttle body
6 Check if the coolant temperature sensor is Yes Next step
working correctly. No Replace
7 Let engine run at idle speed, after coolant Yes Replace ECU
temperature reaches normal value, then use a
No Check the ignition
special short diagnostic tester to check if ignition
timing mechanism
advance angle is normal.
Note: Unsteady idle speed occurs seldom during warming up process, its
troubleshooting is similar to that for previous case, but validate if water temperature
sensor works normally in advance.
12.9. Unsteady Idle Speed after Warming up
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Turn on ignition switch, connect an adaptor Yes Next step
between ECU and harness, and then check if the
No Repair or replace the
voltage between 17# and 42# pins of ECU,
harness
between 39# and 17# pins of ECU (signal output
terminal of intake air temperature sensor and
coolant temperature sensor) as well as 64#, 65#,
66#, 67# pins of ECU (for control of DC motor)
is normal.
3 Turn off the engine. Check the air cleaner and Yes Next step
look if it is open. No Replace
4 After starting successfully, check if air intake Yes Next step
consumption of the engine at idle speed is No Eliminate the leakage
around 300Kg/h (remember to check if cylinder failure of air intake
pressure is normal). system
5 Connect fuel manometer valve. Short 30# and Yes Next step
87# pins of fuel pump relay to make the fuel No 9
pump run, and then check if fuel pressure is
around 400kPa.
6 Use a special joint to directly provide a 12V Yes 8
power supply and intermittent ground wire from No Next step
battery to injector and check if the injector can
work intermittently.
7 Clean out the fuel injector and look if it can Yes Replace
work correctly. No Replace fuel injector
8 Check if fuel is deteroprated or moisture. Yes Replace fuel
No 14
9 Check if the fuel pressure value is below Yes Next step
300kPa. No 13
10 Close the fuel manometer valve. Re-engage the Yes Next step
ignition switch to let the fuel pump run for a No 12
period of time, and then check if fuel pressure
can be built up.
11 Open the valve of fuel gauge and clamp the oil Yes Replace fuel pressure
return pipe by oil return baffle so that the oil can regulator
not return. Check if the oil pressure occurs No Repair and replace
immediately. fuel injector and oil
pipe
12 Check if there is leaking or jam in oil intake Yes Repair or replace oil
pipe. intake pipe
No Replace oil pump
13 Check if the oil return pipe is bended or Yes Repair or replace oil
jammed. return pipe
No Replace fuel pressure
regulator
14 Let engine run at idle speed, after coolant Yes Next step
temperature reaches normal value, then use a No Check other systems
diagnostic tester to check if ignition advance
angle is normal.
15 Pull off the coolant temperature sensor and Yes Replace the coolant
observe if the engine is in right conditions. temperature sensor
No Next step
16 Check if the compression pressure of cylinder is Yes Next step
normal. No Troubleshooting
17 Check if resistance value of ignition cable of Yes Next step
each cylinder is normal (can not exceed 16kÙ). No Replace
18 Check if ignition coil and ignition cable system Yes Replace
works normally and if crack exists on ignition No Next step
coil.
19 Check if the spark plug is in right conditions. Yes Replace ECU
No Replace spark plug
Note: After finish of warming up, engine will enter normal idle speed state, under
which, unsteady revolution is in connection to many factors, such as spark plug, ignition
cable, ignition coil, if air leak exists in the system, if carbon deposit exists in the system
and if cylinder pressure is normal an so forth.
12.10 Unsteady Idle Speed or Extinguish with Load (A/C etc.)
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Turn on A/C switch, connect an adaptor Yes Next step
between ECU and harness, and then measure
No Check and repair air
75# pin of ECU to see if input signal is present
conditioning circuit
(high potential signal loaded by A/C switch
through high and low voltage switches).
3 Check if the pressure of air conditioning system, Yes Next step
the electromagnetic clutch of compressor and No Repair or replace
the air conditioning pump are in right
conditions.
4 Check the voltage on 64#, 65#, 66# and 67# Yes Next step
pins of ECU (for control of DC motor) as well No Check controlling
as corresponding pins on valve body is normal. circuit
5 Remove electronic throttle body and check if Yes Check the electric
throttle is locked or is dumb to run. throttle body
No Next step
6 Start engine, turn on A/C, use a failure diagnosis Yes Replace ECU
tester to read such signals as air intake flow and No Replace the
engine revolution and check if engine electronic throttle
acceleration occurs. body
Note: 75# pin is the up level request signal. When turning on A/C switch, an up level
signal will be sent to ECU through this pin, and then ECU will further check other
systems of A/C. If all systems are normal, ECU will control A/C relay to ground and
A/C system will start to work. 60# pin of ECU is medium voltage signal input; when
high potential signal is loaded on this pin, cooling fan will start and run at high speed.
12.11 Periodic Unsteadiness (Have to Perform Self-study again after ECU
is Power off)
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Check the air cleaner and look if it is open. Yes Next step
No Replace
3 After starting successfully, check if air intake Yes Next step
consumption of the engine at idle speed is around No Check and repair
300Kg/h (remember to check if cylinder pressure air intake and leak
is normal).
4 Let engine run at idle speed, spark out cylinder in Yes 7
turn, and observe if engine revolution will fall and No Next step
fluctuate (it is prohibited to carry out spark out
experiment by disconnecting ignition cable).
5 Turn on ignition switch, connect an adaptor Yes Next step
between ECU and harness, and then check if the
voltage between 17# and 42# pins of ECU,
between 39# and 17# pins of ECU (signal output
terminal of intake air temperature sensor and No Repair or replace
coolant temperature sensor) as well as 64#, 65#, cable
66#, 67# pins of ECU (for control of DC motor) is
normal.
6 Let engine run at idle speed, after coolant Yes Next step
temperature reaches normal value, then use a No Check other part
diagnostic tester to check if ignition advance angle
of the system is normal.
7 Check air intake system for such failures that may Yes Sweep
affect working of engine as blocking and air leak No Next step
etc.
8 Check if fuel is deteroprated or moisture. Yes Replace fuel
No Next step
9 Use a special joint to directly provide a 12V Yes Next step
power supply and intermittent ground wire from No Check and repair
battery to injector and check if the injector can oil injector and
work intermittently. related wires
10 Check if the resistance values of cylinders’ Yes Next step
ignition cable are normal. No Replace
Note: For periodic unsteadiness, mainly check air intake system for air leak or
electronic throttle body for failure. Following are the steps for inspection of electronic
throttle body: while turning on ignition key, throttle may jiggle; during self-checking
procedure, throttle should act with actions of accelerator pedal.
12.12 Too High Idle Speed (Have to Perform Self-study again after ECU is
Power off)
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Check if throttle valve plate is locked and if Yes Adjust or replace
failure exists in electronic throttle body. No Next step
3 Check if the canister control valve, the fuel Yes Repair or replace
pressure regulator, the positive crankcase No Next step
ventilation vacuum pipe and the vacuum pipe of
brake system are mounted steadily or they are
damaged.
4 Run the engine at idle speed and use neutral. Step Yes Next step
on the accelerator and observe if the idle speed is No 6
too high.
5 Clamp the vacuum pipe and observe if the idle Yes Repair or replace
speed becomes normal. the vacuum booster
No Next step
6 Replace PVC valve and clamp the positive Yes Replace PVC valve
crankcase ventilation vacuum pipe. Observe if the No Next step
idle speed becomes normal.
7 Clamp the canister control valve pipe and observe Yes Replace the canister
if the idle speed becomes normal. control valve
No Next step
8 Check if electronic throttle body is dumb or Yes Repair or replace
locked. No Next step
9 Check other parts of air intake pipe for leakage. Yes Repair or replace
No Next step
10 Check if the gasket of fuel injector is in good Yes Next step
condition. No Replace the gasket
11 Check air intake system for air leak and air flow Yes Replace ECU
meter for normal working. No Replace the sensor
Note: Check if the system goes through self-study, if not, the system will be under
failure mode or an uncertain state all the time, which may result in too high idle speed
of engine. The other cause is air leak in the system, if air leakage in the system is too
large and exceeds regulation and control range of ECU, idle speed fluctuation may
occur.
12.13. Engine Revolution Speed is too Low or Flameout
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Check the air cleaner and look if it is open. Yes Next step
No Replace
3 Run the engine at idle speed and check if the Yes Next step
engine revolution speed is normal at idle speed. No Next step,
overhaul with
reference to idle
speed failure
entries
4 After starting successfully, check if air intake Yes Next step
consumption of the engine at idle speed is No Overhaul
around 300Kg/h (remember to check if cylinder
pressure is normal).
5 Let engine run at idle speed, after coolant Yes Next step
temperature reaches normal value, then use a No Check other
diagnostic tester to check if ignition advance systems
angle of the system is normal.
6 Connect fuel manometer valve. Short 30# and Yes Next step
87# pins of fuel pump relay to make the fuel No 10
pump run, and then check if fuel pressure is
around 400kPa.
7 Use a special joint to directly provide a 12V Yes 9
power supply and intermittent ground wire from No Next step
battery to injector and check if the injector can
work intermittently.
8 Clean out the fuel injector and look if it can Yes Next step
work correctly. No Replace fuel
injector
9 Check if fuel is bad or moisture. Yes Replace fuel
No 15
10 Check if the fuel pressure value is below 350 Yes Next step
kPa. No 14
11 Close the fuel manometer valve. Re-engage the Yes Next step
ignition switch to let the fuel pump run for a No 13
period of time, and then check if fuel pressure
can be built up.
12 Open the valve of fuel gauge and clamp the oil Yes Replace fuel
return pipe by oil return baffle so that the oil can pressure regulator
not return. Check if the oil pressure occurs No Repair and replace
immediately. fuel injector and
oil pipe
13 Check if there is leaking or jam in oil intake Yes Repair or replace
pipe. oil intake pipe
No Replace oil pump
14 Check if the oil return pipe is bended or Yes Repair or replace
jammed. oil return pipe
No Replace fuel
pressure regulator
15 Put the ignition switch to “ON”. Check if Yes Next step
voltage on the following pins of ECU is normal:
if it is a battery voltage around 12V on 12#, 14#, No Repair or replace
15# pins; if the voltage between 51#, 53#, 3#, cable
61#, 80# pins and the wire is zero.
16 Check if ignition coil, ignition cable and spark Yes Replace ECU
plug are normal.
No Adjust or replace
the parts involved
Note: This phenomenon indicates a comparatively obvious failure and some minute
details, such as if strainer of the system or exhaust pipe is blocked and so forth, should
also be checked. For other causes, check spark plug and ignition cable etc.
12.14 Slow Response when Accelerating
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 Turn off the engine. Check the air cleaner and Yes Next step
look if it is open. No Replace
3 Run the engine at idle speed and check if the Yes Next step
engine revolution speed is normal at idle speed. No Repair in accordance
with idle speed
failure item
4 Run the engine at idle speed and check if the air Yes Next step
intake pressure is from 35 to 65 kPa. No Overhaul
5 Put the ignition switch to “ON”. Check if it is Yes Next step
break or short circuit between 38#, 32#, 54#, No Repair or replace
36# pins on ECU connector and 1#, 2#, 4#, 6# Harness
pins of throttle position sensor of electronic
throttle valve body.
6 Let engine run at idle speed, after coolant Yes Next step
temperature reaches normal value, then use a No Check other part
diagnostic tester to check if ignition advance
angle is normal.
7 Connect fuel manometer valve. Short 30# and Yes Next step
87# pins of fuel pump relay to make the fuel No 11
pump run, and then check if fuel pressure is
around 4000kPa.
8 Use a special joint to directly provide 12V Yes 10
power supply and intermittent 12V power No Next step
supply from battery to injector and check if the
injector can work intermittently.
9 Clean out the fuel injector and look if it can Yes Next step
work correctly. No Replace fuel injector
12 Close the fuel manometer valve. Re-engage the Yes Next step
ignition switch to let the fuel pump run for a No 14
period of time, and then check if fuel pressure
can be built up.
13 Open the valve of fuel gauge and clamp the oil Yes Replace the pressure
return pipe by oil return baffle so that the oil can regulator
not return. Check if the oil pressure occurs No Repair and replace
immediately. fuel injector and oil
pipe
14 Check if there is leaking or jam in oil intake Yes Repair or replace oil
pipe. intake pipe
No Replace oil pump
15 Check if the oil return pipe is bended or Yes Repair or replace oil
jammed. return pipe
No Replace the pressure
regulator
16 Check if the exhaust system and three-way Yes Replace or clean
catalytic converter are jammed. No Replace ECU
Note: For slow response when accelerating, mainly check air intake pressure and injection pulse-width
etc.; choked exhaust pipe and smudgy air cleaner may be causes for this problem. In addition, spark plug
and ignition cable problems may also be causes.
12.15 Poor Performance and Disability when Accelerating.
Note: Poor acceleration of system relates to many factors, such as problem in mechanical part of the
engine itself, cylinder pressure and carbon deposit on valve etc. In addition, it is also in connection with
other systems, such as power steering system and A/C system.
12.16 Unable to Reach the Maximum Revolution when Accelerating
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 With engine off, check if air cleaner is smooth Yes Next step
(can not simply rely on visualization, remove No Replace
the air cleaner and then perform test drive again)
and if air intake system is chocked.
3 Run the engine at idle speed and check if the Yes Next step
engine revolution speed is normal at idle speed. No Repair in accordance
with idle speed
failure item
4 After starting successfully, check if air intake Yes Next step
consumption of the engine at idle speed is No Overhaul
around 300Kg/h (remember to check if cylinder
pressure is normal).
5 Put the ignition switch to “ON”. Check if it is Yes Next step
break or short circuit between 38#, 32#, 54#, No Repair or replace
36# pins on ECU connector and 1#, 2#, 4#, 6# Harness
pins of throttle position sensor of electronic
throttle valve body.
6 Let engine run at idle speed, after coolant Yes Next step
temperature reaches normal value, then use a No Check other part
diagnostic tester to check if ignition advance
angle is normal.
7 Connect fuel manometer valve. Short 30# and Yes Next step
87# pins of fuel pump relay to make the fuel No 11
pump run, and then check if fuel pressure is
around 400kPa.
8 Check if working positions of camshaft position Yes Next step
sensor and crankshaft position sensor are No Replace the parts
normal. involved
9 Clean out the fuel injector and look if it can Yes Next step
work correctly. No Replace fuel injector
Note: In case the engine is unable to reach its maximum revolution when accelerating, mainly check if
exhaust pipe is chocked and air cleaner is smudgy. In addition, for electric control system of A21, in case
of a failure in crankshaft or camshaft position sensor, ECU will take restrictive driving measures to
restrict engine revolution to exceed certain value, which should be noted during maintenance process.
12.17 When Releasing Accelerator Pedal after Acceleration, Unsteady Idle
1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
diagnostic tester to check if any failure displayed
information record exists. No Next step
2 With engine off, check if air cleaner is smooth Yes Next step
(can not simply rely on visualization, remove No Replace
the air cleaner and then perform test drive again)
and if air intake system is chocked.
3 Run the engine at idle speed and check if the Yes Next step
engine revolution speed is normal at idle speed. No Repair in accordance
with idle speed
failure item
4 After starting successfully, check if air intake Yes Next step
consumption of the engine at idle speed is No Overhaul
around 300Kg/h (remember to check if cylinder
pressure is normal).
5 Put the ignition switch to “ON”. Check if it is Yes Next step
break or short circuit between 38#, 32#, 54#, No Repair or replace
36# pins on ECU connector and 1#, 2#, 4#, 6# Harness
pins of throttle position sensor of electronic
throttle valve body.
6 Let engine run at idle speed, after coolant Yes Next step
temperature reaches normal value, then use a No Check other part
diagnostic tester to check if ignition advance
angle is normal.
7 Connect fuel manometer valve. Short 30# and Yes Next step
87# pins of fuel pump relay to make the fuel No 11
pump run, and then check if fuel pressure is
around 400kPa.
8 Remove air intake hose, check if carbon deposit Yes Clear carbon deposit
or other soil (this may result in air intake system No Next step
of engine being chocked when the valve plate
closes) exists.
9 Clean out the fuel injector and look if it can Yes Next step
work correctly. No Replace fuel injector
Note: For an electric control motor with the electronic throttle body, the main actuators of its air intake
system are air flow meter and electronic throttle body. Air flow meter has very high operational reliability
and very low failure rate, while, due to particularity of road status in China and affected by operating
environment, choke is liable to occur between valve plate and valve body of the electronic throttle body,
which may obstruct air from entering the engine and result in extinguish of engine.
12.18 A/C System Failure
1 Check if there is enough coolant, if the A/C belt, Yes Next step
the A/C clutch and the pressure switch are in No Troubleshooting
good condition.
2 Let engine run at idle speed and turn on A/C Yes Remove the failure
switch. Enter A/C self diagnosis mode to check displayed
the A/C system for failure. No Next step
3 Turn on the A/C switch and connect an adaptor Yes Next step
between ECU and harness. Measure 75# pin No Check the harness
(A/C switch) of ECU and see if there are input
signals on it.
4 If this vehicle adopts low level control, check if Yes Replace or repair the
the air condition is working still even though it harness
is turned off. No Next step
5 Check if there is low level output at ECU pin Yes Repair the A/C
No.69 (connect to the ground of pull in winding replay and harness
of A/C relay). No Replace ECU
Note: Different from the controlling means of other models, the A/C control system of A21 adopts the
automatic A/C and uses double-pressure switch to control incorporation of the A/C system and the fan
after A/C starts up.
13. Safety Precautions for System Maintenance
(1) Disassembly and assembly requirements for electronic control unit (ECU):
(2) Requirements for cleanness: the following rules should be observed for any
operation on oil-supply system and oil-injection system:
The parts removed should be place at a clean site and covered properly; do not use the
cloth (cotton cloth and gauze) with falling off fibre;
(3) Connect and disconnect the connectors of all sorts of harnesses and the connectors
of failure diagnosis testers only after the ignition switch is turned off.
When measuring mains voltage or ground wire grounding of the electronic control
system, be sure to check if the connection order and mode are correct;
Disconnect power cord or ground wire of battery from the system and disconnect
harness connector of ECU; both operation modes above may cause loss of information
about diagnosis and self-study stored in ECU (the retention time of information after the
ECU installed is power off depends on the model).
(4) Attentions during maintenance of fuel feed system (fuel feed line, fuel pump
and fuel injection system):
Disassembly or installation of oil pump on the tank full of oil or partly full of oil,
please note:
Before operation, get material ready near the fuel tank opening for absorption of heavy
discharging fuel, so that, the fuel discharged can be duly absorbed;
Avoid skin from direct contact with gasoline as best as you can;
Before loosening a connection part, thoroughly clean this part and the area around the
connecting pieces;
Dishcloth shall be placed around the connecting part for avoide oil-spraying;
If disassembled parts can not be repaired or for other processing immediately, store
them properly.
The spare parts can be taken out of their package only when they are to be installed; do
not use the spare parts without package or with package heavily damaged;
When installing an injector, be careful not to damage the O-gaskets at both ends of the
injector; for installation convenience, apply a little lubricant on the O-gaskets.
After fuel and fuel feed systems are disassembled, avoid use of compressed air and
move of the vehicle as best as you can.